Elastically deformable clip and method

Abstract

An elastically deformable clip includes a first and second outer wall arranged substantially parallel to each other, each of the first outer wall and the second outer wall having an inner surface, an outer surface, a first edge and a second edge arranged substantially parallel, and a third edge and a fourth edge arranged substantially parallel. The clip also includes at least one inner wall extending between the inner surfaces of the first and second outer walls, the at least one inner wall having at least one slot, wherein the first outer wall, the second outer wall and the at least one inner wall are formed of an elastically deformable material. The clip further includes a rib protruding from the outer surface of at least one of the first and second outer walls, the rib arranged substantially parallel to the first edge and the second edge.

Description

FIELD OF THE INVENTION

The invention relates to components to be mated together and, more particularly, to an elastically deformable clip for a clip assembly, as well as a method of mating and retaining components with the elastically deformable clip.

BACKGROUND

Currently, components which are to be mated together in a manufacturing process are subject to positional variation based on the mating arrangements between the components. One common arrangement includes components mutually located with respect to each other by 2-way and/or 4-way male alignment features; typically undersized male structures which are received into corresponding oversized female alignment features such as apertures in the form of openings and/or slots. Alternatively, double-sided tape, adhesives or welding processes may be employed to mate parts. Irrespective of the precise mating arrangement, there is a clearance between at least a portion of the alignment features which is predetermined to match anticipated size and positional variation tolerances of the mating features as a result of manufacturing (or fabrication) variances. As a result, occurrence of significant positional variation between the mated components is possible, which may contribute to the presence of undesirably large and varying gaps and otherwise poor fit. The clearance between the aligning and attaching features may lead to relative motion between mated components, which may contribute to poor perceived quality. Additional undesirable effects may include squeaking and rattling of the mated components, for example.

SUMMARY OF THE INVENTION

In one exemplary embodiment, a clip assembly having an elastically deformable clip is provided. The elastically deformable clip includes a first outer wall and a second outer wall arranged substantially parallel to each other, each of the first outer wall and the second outer wall having an inner surface, an outer surface, a first edge and a second edge arranged substantially parallel to each other, and a third edge and a fourth edge arranged substantially parallel to each other. The clip also includes at least one inner wall extending between the inner surfaces of the first outer wall and the second outer wall, the at least one inner wall having at least one slot, wherein the first outer wall, the second outer wall and the at least one inner wall are formed of an elastically deformable material. The clip further includes a rib protruding from the outer surface of at least one of the first outer wall and the second outer wall, the rib arranged substantially parallel to the first edge and the second edge.

In another exemplary embodiment, clip assembly having an elastically deformable clip is provided. The elastically deformable clip includes a first outer wall and a second outer wall arranged substantially parallel to each other, each of the first outer wall and the second outer wall having an inner surface, an outer surface, a first edge and a second edge arranged substantially parallel to each other, and a third edge and a fourth edge arranged substantially parallel to each other. The clip also includes at least one inner wall extending between the inner surfaces of the first outer wall and the second outer wall. The clip further includes a first rib protruding from the outer surface of at least one of the first outer wall and the second outer wall, the first rib arranged substantially parallel to the third edge and disposed in close proximity to the third edge. The clip yet further includes a second rib protruding from the outer surface of at least one of the first outer wall and the second outer wall, the rib arranged substantially parallel to the fourth edge and disposed in close proximity to the fourth edge.

In yet another exemplary embodiment, a method of mating components is provided. The method includes aligning a component having an aperture with an elastically deformable clip having an H-shaped geometry formed of an inner wall and a pair of outer walls. The method also includes translating the elastically deformable clip within the aperture. The method further includes engaging a rib protruding from an outer surface of at least one of the outer walls with an aperture wall. The method yet further includes elastically deforming the inner wall upon translation of the elastically deformable clip. The method also includes snap-fitting the elastically deformable clip into a fully engaged position upon translation of the rib to an over-center position of the rib with the aperture wall.

The above features and advantages and other features and advantages of the invention are readily apparent from the following detailed description of the invention when taken in connection with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Other features, advantages and details appear, by way of example only, in the following detailed description of embodiments, the detailed description referring to the drawings in which:

FIG. 1 is a perspective view of an elastically deformable clip according to a first embodiment;

FIG. 2 is a perspective view of the elastically deformable clip of FIG. 1 in a partially engaged position with a component;

FIG. 3 is a cross-sectional view taken along line 3-3 of FIG. 2 of the elastically deformable clip of FIG. 1 in a partially engaged position with the component;

FIG. 4 is a cross-sectional view of the elastically deformable clip of FIG. 1 in a fully engaged position with the component;

FIG. 5 is a perspective view of the elastically deformable clip according to a second embodiment;

FIG. 6 is a top view of the elastically deformable clip of FIG. 5;

FIG. 7 is a perspective view of the elastically deformable clip of FIG. 5 in a partially engaged position with the component;

FIG. 8 is a cross-sectional view taken along line 8-8 of FIG. 7 of the elastically deformable clip of FIG. 4 in a fully engaged position with the component; and

FIG. 9 is a flow diagram illustrating a method of mating components with the elastically deformable clip.

DESCRIPTION OF THE EMBODIMENTS

The following description is merely exemplary in nature and is not intended to limit the present disclosure, its application or uses. For example, the embodiments shown are applicable to vehicle interior component assemblies, such as garnish moldings and trim components, but the embodiments disclosed herein may be used with any suitable components to provide elastic averaging for precision location and alignment of all manner of mating components and component applications, including many industrial, consumer product (e.g., consumer electronics, various appliances and the like), transportation, energy and aerospace applications, and particularly including many other types of vehicular components and applications, such as various interior, exterior and under hood vehicular components and applications. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.

Referring to FIG. 1, an elastically deformable clip 10 according to a first embodiment is illustrated. The elastically deformable clip 10 includes an inner wall 12 extending between, and connecting, a first outer wall 14 and a second outer wall 16. In particular, the inner wall 12 contacts and extends between an inner surface 18 of the outer walls 14, 16. In addition to the inner surface 18, both outer walls 14, 16 include an outer surface 20, a first edge 22, a second edge 24, a third edge 26 and a fourth edge 28. The outer walls 14, 16 in the illustrated embodiment each have a substantially parallelogram geometry, such as a square or rectangle, for example. In particular, the first edge 22 and the second edge 24 are arranged substantially parallel to each other, with the third edge 26 and the fourth edge 28 arranged substantially parallel to each other. Although illustrated and described above as a parallelogram, it is to be understood that the geometry of the outer walls 14, 16 may deviate from that shown in the exemplary embodiment. Additionally, the outer walls 14, 16 may be formed of geometries distinct from each other. In one embodiment, in combination, the inner wall 12 and the outer walls 14, 16 form a substantially H-shaped geometry, but alternative orientations are contemplated.

The inner wall 12 includes a first edge 30 and a second edge 32 that typically correspond to common respective planes of the first edge 22 and the second edge 24 of the outer walls 14, 16, but the precise location of the first and second edges 30, 32 of the inner wall 12 may vary relative to the edges 22, 24 of the outer walls 14, 16. At least one slot 34 is included in the inner wall 12. In the illustrated embodiment, two slots are shown; however, it is to be appreciated that any number of slots may be employed, depending on the desired flexibility of the overall elastically deformable clip 10, as will be appreciated from the description below. The at least one slot 34 extends from the first edge 30 of the inner wall 12 to a terminal end 36.

Protruding from the outer surface 20 of at least one of the outer walls 14, 16 is a rib 40. For purposes of discussion, the rib 40 is shown and described as being included along the second outer wall 16, but it is to be appreciated that either or both outer wall 14, 16, or any additional portion around the perimeter of the outer walls 14, 16, may include the rib 40. Although it is contemplated that the rib 40 is merely assembled with the outer wall 16, typically the rib 40 is integrally formed with the outer wall 16. Furthermore, the inner wall 12 may be operatively coupled to the outer walls 14, 16, but typically the entire elastically deformable clip 10 is integrally formed as a single molded component. The ribs 40 are aligned in a substantially parallel manner with the first edge 22 and the second edge 24 of the outer walls 14, 16. The ribs 40 may fully extend from the third edge 26 to the fourth edge 28 or along intermediate locations therebetween. In one embodiment, the ribs 40 are located approximately equidistant between the first edge 22 and the second edge 24 of the outer walls 14, 16. Irrespective of the precise location of the ribs 40, the terminal end 36 of the at least one slot 34 is disposed closer in proximity to the second edge 24 of the outer wall 16 than that of the rib 40. Positioning in this manner facilitates flexing and/or elastic deformation of one or both of the outer walls 14, 16 during translation along a mating component edge upon insertion of the elastically deformable clip 10 into an aperture, as will be described in detail below. To facilitate insertion, as will be appreciated from the description below, the outer walls 14, 16 and the inner wall 12 may be formed of an elastically deformable material.

Any suitable elastically deformable material may be used for the elastically deformable clip 10. The term “elastically deformable” refers to components, or portions of components, including component features, comprising materials having a generally elastic deformation characteristic, wherein the material is configured to undergo a resiliently reversible change in its shape, size, or both, in response to application of a force. The force causing the resiliently reversible or elastic deformation of the material may include a tensile, compressive, shear, bending or torsional force, or various combinations of these forces. The elastically deformable materials may exhibit linear elastic deformation, for example that described according to Hooke's law, or non-linear elastic deformation.

Numerous examples of materials that may at least partially form the components include various metals, polymers, ceramics, inorganic materials or glasses, or composites of any of the aforementioned materials, or any other combinations thereof. Many composite materials are envisioned, including various filled polymers, including glass, ceramic, metal and inorganic material filled polymers, particularly glass, metal, ceramic, inorganic or carbon fiber filled polymers. Any suitable filler morphology may be employed, including all shapes and sizes of particulates or fibers. More particularly any suitable type of fiber may be used, including continuous and discontinuous fibers, woven and unwoven cloths, felts or tows, or a combination thereof. Any suitable metal may be used, including various grades and alloys of steel, cast iron, aluminum, magnesium or titanium, or composites thereof, or any other combinations thereof. Polymers may include both thermoplastic polymers or thermoset polymers, or composites thereof, or any other combinations thereof, including a wide variety of co-polymers and polymer blends. In one embodiment, a preferred plastic material is one having elastic properties so as to deform elastically without fracture, as for example, a material comprising an acrylonitrile butadiene styrene (ABS) polymer, and more particularly a polycarbonate ABS polymer blend (PC/ABS), such as an ABS acrylic. The material may be in any form and formed or manufactured by any suitable process, including stamped or formed metal, composite or other sheets, forgings, extruded parts, pressed parts, castings, or molded parts and the like, to include the deformable features described herein. The material, or materials, may be selected to provide a predetermined elastic response characteristic of the elastically deformable clip 10. The predetermined elastic response characteristic may include, for example, a predetermined elastic modulus.

Referring to FIGS. 2 and 3, the elastically deformable clip 10 is illustrated in use as part of a clip assembly 50 for mating components. Specifically, the clip assembly 50 includes the elastically deformable clip 10, which is operatively coupled to or integrally formed with a first component 52 (FIG. 3), and a second component 54 to be mated with the first component 52. The elastically deformable clip 10 is shown in a partially inserted, or partially engaged, condition, with respect to an aperture 56 defined by an aperture wall 58 formed in the second component 54. At least a portion of the aperture wall 58 includes a chamfered region 60, thereby providing a “lead-in” guide to facilitate initial insertion of the elastically deformable clip 10. As best shown in FIGS. 3 and 4, the outer wall(s) 14, 16 are configured to engage the aperture wall 58 and elastically deform in a flexing manner upon contact with the aperture wall 58 during translation of the elastically deformable clip 10 within the aperture 56. As the outer wall(s) 14, 16 engage the aperture wall 58, the outer walls 14, 16 and a portion of the inner wall 12 rotate inwardly in an elastically deformable manner, thereby compressing the inner wall slots, as shown with directional arrow Z. The deformability of the clip 10 can be appreciated from the description above, as it relates to the material and elastic deformability of the clip 10. The flexibility is further facilitated by the presence of the slots 34 formed in the inner wall 12. The void of material in wall 12 enhances the flexibility of the outer wall(s) 14, 16. Contact between the outer walls 14, 16 and the aperture 58 is ensured by sizing the clip 10 to be larger in a direction X than that of the aperture 56.

Referring now to FIG. 4, the elastically deformable clip 10 is shown in a fully engaged, or inserted, condition. The illustrated condition is achieved upon translation of the clip 10 throughout the aperture 56 in a direction Y. Translation is made until the rib 40 engages, by sliding past the aperture wall 58, to an “over-center” condition. The over-center condition of the rib 40 is defined as more than half of the rib 40 having passed over the aperture wall 58. Upon snap-fitting the clip 10 through the aperture 56, a reliable mating of the first component 52 and the second component 54 is achieved, while eliminating any associated gaps between the clip 10 and the aperture wall 56. It is to be appreciated that a slight interference condition between the rib 40 and the aperture wall 58 is present subsequent to passage of the rib 40 to the over-center condition.

Referring to FIG. 5, an elastically deformable clip 100, according to a second embodiment, is illustrated. The clip 100 is similar in many respects to the first embodiment described in detail above, such that duplicative discussion of similar features and functionality are not necessary. The clip 100 includes an inner wall 112, a first outer wall 114 and a second outer wall 116. As shown, the clip 100 may be formed with an H-shaped geometry, but alternatives are contemplated, as is the case with the first embodiment. The inner wall 112 may comprise a solid member and extends between respective inner surfaces 118 of the outer walls 114, 116. At least one of the outer walls 114, 116 includes a first rib 120 and a second rib 122 protruding from an outer surface 124 of the outer walls 114, 116. Although either or both outer wall may include the ribs, only the second outer wall 116 will be described as having a rib thereon. As with the first embodiment, the outer wall 116 may be formed of an elastically deformable material to facilitate bending of the outer wall 116 upon contact with a mating component, as will be discussed in detail below.

The ribs 120, 122 are arranged substantially parallel to the third edge 26 and the fourth edge 28; however, disposal of the ribs 120, 122 at an angle thereto is contemplated. The first rib 120 is disposed in close proximity to the third edge 26 and the second rib 122 is disposed in close proximity to the fourth edge 28. Each of the ribs 120, 122 may fully extend from the first edge 22 to the second edge 24 or along intermediate locations therebetween. Irrespective of the precise positioning of the ribs 120, 122, each rib extends at an angle from a first end 126 to an intermediate location 128. The intermediate location 128 corresponds to an outermost location of the ribs 120, 122, relative to a distance away from the outer surface 124 of the outer wall 116. The ribs 120, 122 angle inwardly from the intermediate location 128 to a second end 130. The intermediate location 128 provides a clip retention point, as described below.

Referring to FIGS. 6-8, the clip 100 is shown at various stages of engagement with the aperture wall 58 of the second component 54. Specifically, in a partially engaged, or inserted, condition (FIG. 6) of the clip 100, engagement between the ribs 120, 122 biases regions of the outer wall 116 to flex inwardly in an arcuate manner (Z) around the inner wall 112 in an elastically deformable manner. As discussed above, such deformation is achieved by the elastically deformable material from which the clip 100 is constructed. Upon sufficient translation of the clip 100 within the aperture 56, the intermediate location 128 of the ribs 120, 122 “snaps” over the aperture wall 58 and imposes a retention force, thereby mating the first component 52 and the second component 54.

In one embodiment, a plurality of clips 10, 100 are employed to mate the first component 52 to the second component 54. The plurality of clips may be employed within a single aperture or in a plurality of corresponding apertures. In either event, the elastic deformability allows the components to be mated in a precisely aligned manner by “elastically averaging” offsets associated with manufacturing and tolerance issues

Elastic averaging provides elastic deformation of the interface(s) between mated components, wherein the average deformation provides a precise alignment, the manufacturing positional variance being minimized to X_min, defined by X_min=X/√N, wherein X is the manufacturing positional variance of the locating features of the mated components and N is the number of features inserted. To obtain elastic averaging, an elastically deformable component is configured to have at least one feature and its contact surface(s) that is over-constrained and provides an interference fit with a mating feature of another component and its contact surface(s). The over-constrained condition and interference fit resiliently reversibly (elastically) deforms at least one of the at least one feature or the mating feature, or both features. The resiliently reversible nature of these features of the components allows repeatable insertion and withdrawal of the components that facilitates their assembly and disassembly. In some embodiments, the elastically deformable component configured to have the at least one feature and associated mating feature disclosed herein may require more than one of such features, depending on the requirements of a particular embodiment. Positional variance of the components may result in varying forces being applied over regions of the contact surfaces that are over-constrained and engaged during insertion of the component in an interference condition. It is to be appreciated that a single inserted component may be elastically averaged with respect to a length of the perimeter of the component. The principles of elastic averaging are described in detail in commonly owned, co-pending U.S. patent application Ser. No. 13/187,675, now U.S. Publication No. U.S. 2013-0019455, the disclosure of which is incorporated by reference herein in its entirety. The embodiments disclosed above provide the ability to convert an existing component that is not compatible with the above-described elastic averaging principles to an assembly that does facilitate elastic averaging and the benefits associated therewith.

A method of mating components 200 is also provided, as illustrated in FIG. 9, and with reference to FIGS. 1-8. The elastically deformable clip 10, 100, and more specifically the elastically deformable nature of clip, has been previously described and specific structural components need not be described in further detail. The method 200 includes aligning 202 a component having an aperture 56 with the elastically deformable clip 10, 100 having an H-shaped geometry formed of an inner wall 12, 112 and outer walls 14, 16, 114, 116. The elastically deformable clip 10, 100 is translated 204 within the aperture 56. The rib 40, 120, 122, is engaged 206 with the aperture wall 58. At least one of the outer walls are elastically deformed 208 upon translation of the elastically deformable clip until the clip is snap-fitted 210 into a fully engaged position upon translation of the rib to an over-center position of the rib with the aperture wall.

While the invention has been described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiments disclosed, but that the invention will include all embodiments falling within the scope of the application.

Claims

1. An elastically deformable clip comprising:

a first outer wall and a second outer wall arranged substantially parallel to each other, each of the first outer wall and the second outer wall having an inner surface, an outer surface, a first edge and a second edge arranged substantially parallel to each other, and a third edge and a fourth edge arranged substantially parallel to each other;

at least one inner wall extending between the inner surfaces of the first outer wall and the second outer wall, the at least one inner wall having at least one slot, wherein the first outer wall, the second outer wall and the at least one inner wall are formed of an elastically deformable material; and

a rib protruding from the outer surface of at least one of the first outer wall and the second outer wall, the rib arranged substantially parallel to the first edge and the second edge.

2. The elastically deformable clip of claim 1, wherein the first outer wall, the second outer wall and the inner wall form an H-shaped cross-section.

3. The elastically deformable clip of claim 1, the rib extending from the third edge to the fourth edge.

4. The elastically deformable clip of claim 1, the rib located approximately equidistant from the first edge and the second edge.

5. The elastically deformable clip of claim 1, wherein the entire clip is a molded component.

6. The elastically deformable clip of claim 1, wherein the at least one slot extends from a first edge of the inner wall to a location closer in proximity to the second edge of the outer walls than the proximity of the rib to the second edge.

7. The elastically deformable clip of claim 1, wherein the elastically deformable clip is configured to mate components of an assembly comprising:

a first component operatively coupled to the elastically deformable clip; and

a second component having an aperture engageable with the clip for mating the first component with the second component.

8. The elastically deformable clip of claim 7, wherein the clip assembly is disposed in a vehicle.

9. The elastically deformable clip of claim 7, wherein the first component and the second component are configured to engage each other in a fully engaged condition, wherein the rib is engaged with an aperture wall of the aperture in an over-center position.

10. The elastically deformable clip of claim 9, wherein the entire clip is formed of an elastically deformable material.

11. The elastically deformable clip of claim 10, wherein a portion proximate the first edge of at least one of the first outer wall and the second outer wall is configured to elastically deform during contact with the aperture wall of the second component.

12. The elastically deformable clip of claim 10, further comprising a plurality of elastically deformable clips operatively coupled to the first component and a plurality of apertures of the second component configured to receive the plurality of elastically deformable clips, wherein the fully engaged condition comprises contact interference between the plurality of elastically deformable clips and the plurality of apertures, wherein an amount of deformation of the plurality of elastically deformable clips is averaged in aggregate to elastically average the position of the first component relative to the second component.